Contribution to FE modeling for intraoperative pedicle screw strength prediction

Craniocaudal toggling increases the risk of screw loosening in osteoporotic vertebrae

BACKGROUND AND OBJECTIVE

Screw loosening remains a prominent problem for osteoporotic patients undergoing pedicle screw fixation surgeries but its underlying mechanisms are not fully understood. This study sought to examine the interactive effect of craniocaudal or axial cyclic loading (toggling) and osteoporosis on screw fixation.

METHODS

QCT-based finite element models of normal (n = 7; vBMD = 156 ± 13 mg/cm³) and osteoporotic vertebrae (n = 7; vBMD = 72 ± 6 mg/cm³) were inserted with pedicle screws and loaded with or without craniocaudal toggling. Among them, a representative normal vertebra (age: 55; BMD: 140 mg/cm³) and an osteoporotic vertebra (age: 64; BMD: 79 mg/cm³) were also loaded with or without axial toggling. The individual and interactive effects of craniocaudal toggling and osteoporosis on screw fixation strength (the force when the pull-up displacement of the screw head reached 1 mm) and bone tissue failure (characterized by equivalent plastic strain) were examined by repeated measure ANOVA.

RESULTS

A significant interactive effect between craniocaudal toggling and osteoporosis on screw fixation strength was detected (p = 0.008). Specifically, craniocaudal toggling led to a marked decrease in the fixation strength (68%, p < 0.05) and stiffness (83%, p < 0.05) only in the osteoporotic vertebrae but had no effect on screw fixation strength and stiffness of the normal vertebrae (p > 0.05). Likewise, most of the bone tissues around the screw in the osteoporotic vertebrae yielded following craniocaudal toggling whereas this result was not seen in the normal vertebrae. The axial toggling had no significant effect on bone tissue failure as well as pedicle screw fixation in normal or osteoporotic vertebrae.

CONCLUSIONS

Craniocaudal toggling substantially reduces the screw fixation strength of the osteoporotic vertebrae by progressively increasing tissue failure around the screw, and therefore may contribute to the higher rates of screw loosening in osteoporotic compared to normal patients, whereas axial toggling is not a risk factor for pedicle screw loosening in normal or osteoporotic patients.

Location of pedicle screw hold in relation to bone quality and loads

Introduction: Sufficient screw hold is an indispensable requirement for successful spinal fusion, but pedicle screw loosening is a highly prevalent burden. The aim of this study was to quantify the contribution of the pedicle and corpus region in relation to bone quality and loading amplitude of pedicle screws with traditional trajectories.

Methods: After CT examination to classify bone quality, 14 pedicle screws were inserted into seven L5. Subsequently, Micro-CT images were acquired to analyze the screw’s location and the vertebrae were split in the midsagittal plane and horizontally along the screw’s axis to allow imprint tests with 6 mm long sections of the pedicle screws in a caudal direction perpendicular to the screw’s surface. Force-displacement curves in combination with the micro-CT data were used to reconstruct the resistance of the pedicle and corpus region at different loading amplitudes.

Results: Bone quality was classified as normal in three specimens, as moderate in two and as bad in two specimens, resulting in six, four, and four pedicle screws per group. The screw length in the pedicle region in relation to the inserted screw length was measured at an average of 63%, 62%, and 52% for the three groups, respectively. At a calculated 100 N axial load acting on the whole pedicle screw, the pedicle region contributed an average of 55%, 58%, and 58% resistance for the normal, moderate, and bad bone quality specimens, respectively. With 500 N load, these values were measured at 59%, 63%, and 73% and with 1000 N load, they were quantified at 71%, 75%, and 81%.

Conclusion: At lower loading amplitudes, the contribution of the pedicle and corpus region on pedicle screw hold are largely balanced and independent of bone quality. With increasing loading amplitudes, the contribution of the pedicle region increases disproportionally, and this increase is even more pronounced in situations with reduced bone quality. These results demonstrate the importance of the pedicle region for screw hold, especially for reduced bone quality.

A Novel Screw Modeling Approach to Study the Effects of Screw Parameters on Pullout Strength

Screw loosening remains a prominent problem for osteoporotic patients undergoing pedicle screw fixation surgeries and is affected by screw parameters (e.g., diameter, pitch and thread angle). However, the individual and interactive effects of these parameters on screw fixation are not fully understood. Furthermore, current finite element modeling of an threaded screw is less computationally efficient. To address these issues, we (1) explored a novel "simulated threaded screw" approach (virtual threads assigned to the contact elements of a simplified screw) and compared its performance with threaded and simplified screws, and (2) examined with this approach the individual and interactive effects of altering screw diameter (5.5-6.5 mm), pitch (1-2 mm) and half-thread angle (20-30°) on pullout strength of normal vertebrae. Results demonstrated that the "simulated threaded screw" approach equivalently predicted pullout strength compared to the "threaded screw" approach (R2 = 0.99, slope = 1). We further found that the pullout strength was most sensitive to the change in screw diameter, followed by thread angle, pitch and interactions of diameter*pitch or diameter*angle. In conclusion, the "simulated threaded screw" approach can achieve the same predictive capability compared to threaded modeling of the screw. The current findings may serve as useful references for planning of screw parameters, so as to improve the complication of screw loosening.

Finite Element Analysis of Fracture Fixation

PURPOSE OF REVIEW

Fracture fixation aims to provide stability and promote healing, but remains challenging in unstable and osteoporotic fractures with increased risk of construct failure and nonunion. The first part of this article reviews the clinical motivation behind finite element analysis of fracture fixation, its strengths and weaknesses, how models are developed and validated, and how outputs are typically interpreted. The second part reviews recent modeling studies of the femur and proximal humerus, areas with particular relevance to fragility fractures.

RECENT FINDINGS

There is some consensus in the literature around how certain modeling aspects are pragmatically formulated, including bone and implant geometries, meshing, material properties, interactions, and loads and boundary conditions. Studies most often focus on predicted implant stress, bone strain surrounding screws, or interfragmentary displacements. However, most models are not rigorously validated. With refined modeling methods, improved validation efforts, and large-scale systematic analyses, finite element analysis is poised to advance the understanding of fracture fixation failure, enable optimization of implant designs, and improve surgical guidance.

Patient-Specific Finite Element Models of Posterior Pedicle Screw Fixation: Effect of Screw's Size and Geometry

Pedicle screw fixation is extensively performed to treat spine injuries or diseases and it is common for thoracolumbar fractures. Post-operative complications may arise from this surgery leading to back pain or revisions. Finite element (FE) models could be used to predict the outcomes of surgeries but should be verified when both simplified and realistic designs of screws are used. The aim of this study was to generate patient-specific Computed Tomography (CT)-based FE models of human vertebrae with two pedicle screws, verify the models, and use them to evaluate the effect of the screws' size and geometry on the mechanical properties of the screws-vertebra structure. FE models of the lumbar vertebra implanted with two pedicle screws were created from anonymized CT-scans of three patients. Compressive loads were applied to the head of the screws. The mesh size was optimized for realistic and simplified geometry of the screws with a mesh refinement study. Finally, the optimal mesh size was used to evaluate the sensitivity of the model to changes in screw's size (diameter and length) and geometry (realistic or simplified). For both simplified and realistic models, element sizes of 0.6 mm in the screw and 1.0 mm in the bone allowed to obtain relative differences of approximately 5% or lower. Changes in screw's length resulted in 4-10% differences in maximum deflection, 1-6% differences in peak stress in the screws, 10-22% differences in mean strain in the bone around the screw; changes in screw's diameter resulted in 28-36% differences in maximum deflection, 6-27% differences in peak stress in the screws, and 30-47% differences in mean strain in the bone around the screw. The maximum deflection predicted with realistic or simplified screws correlated very well (R ² = 0.99). The peak stress in screws with realistic or simplified design correlated well (R ² = 0.82) but simplified models underestimated the peak stress. In conclusion, the results showed that the diameter of the screw has a major role on the mechanics of the screw-vertebral structure for each patient. Simplified screws can be used to estimate the mechanical properties of the implanted vertebrae, but the systematic underestimation of the peak stress should be considered when interpreting the results from the FE analyses.

Ultra-high-molecular-weight polyethylene sublaminar tape as semirigid fixation or pedicle screw augmentation to prevent failure in long-segment spine surgery: an ex vivo biomechanical study

OBJECTIVE

Complications after adult spinal deformity surgery are common, with implant-related complications occurring in up to 27.8% of cases. Sublaminar wire fixation strength is less affected by decreasing trabecular bone density in comparison to pedicle screw (PS) fixation due to the predominant cortical bone composition of the lamina. Sublaminar fixation may thus aid in decreasing implant-related complications. The goal of this study was to compare fixation characteristics of titanium sublaminar cables (SCs), ultra-high-molecular-weight polyethylene (UHMWPE) tape, PSs, and PSs augmented with UHMWPE tape in an ex vivo flexion-bending setup.

METHODS

Thirty-six human cadaver vertebrae were stratified into 4 different fixation groups: UHMWPE sublaminar tape (ST), PS, metal SC, and PS augmented with ST (PS + ST). Individual vertebrae were embedded in resin, and a flexion-bending moment was applied that closely resembles the in vivo loading pattern at transitional levels of spinal instrumentation.

RESULTS

The failure strength of PS + ST (4522 ± 2314 N) was significantly higher compared to the SC (2931 ± 751 N) and PS (2678 ± 827 N) groups, which had p values of 0.028 and 0.015, respectively (all values expressed as the mean ± SD). Construct stiffness was significantly higher for the PS groups compared to the stand-alone sublaminar wiring groups (p = 0.020). In contrast to SC, ST did not show any case of cortical breach.

CONCLUSIONS

The higher failure strength of PS + ST compared to PS indicates that PS augmentation with ST may be an effective measure to reduce the incidence of screw pullout, even in osteoporotic vertebrae. Moreover, the lower stiffness of sublaminar fixation techniques and the absence of damage to the cortices in the ST group suggest that ST as a stand-alone fixation technique in adult spinal deformity surgery may also be clinically feasible and offer clinical benefits.

Development of a Computer-Aided Design and Finite Element Analysis Combined Method for Affordable Spine Surgical Navigation With 3D-Printed Customized Template

Introduction: Revision surgery of a previous lumbosacral non-union is highly challenging, especially in case of complications, such as a broken screw at the first sacral level (S1). Here, we propose the implementation of a new method based on the CT scan of a clinical case using 3D reconstruction, combined with finite element analysis (FEA), computer-assisted design (CAD), and 3D-printing technology to provide accurate surgical navigation to aid the surgeon in performing the optimal surgical technique by inserting a pedicle screw at the S1 level.

Materials and Methods: A step-by-step approach was developed and performed as follows: (1) Quantitative CT based patient-specific FE model of the sacrum was created. (2) The CAD model of the pedicle screw was inserted into the sacrum model in a bicortical convergent and a monocortical divergent position, by overcoming the geometrical difficulty caused by the broken screw. (3) Static FEAs (Abaqus, Dassault Systemes) were performed using 500 N tensile load applied to the screw head. (4) A template with two screw guiding structures for the sacrum was designed and manufactured using CAD design and 3D-printing technologies, and investment casting. (5) The proposed surgical technique was performed on the patient-specific physical model created with the FDM printing technology. The patient-specific model was CT scanned and a comparison with the virtual plan was performed to evaluate the template accuracy

Results: FEA results proved that the modified bicortical convergent insertion is stiffer (6,617.23 N/mm) compared to monocortical divergent placement (2,989.07 N/mm). The final template was created via investment casting from cobalt-chrome. The template design concept was shown to be accurate (grade A, Gertzbein-Robbins scale) based on the comparison of the simulated surgery using the patient-specific physical model and the 3D virtual surgical plan.

Conclusion: Compared to the conventional surgical navigation techniques, the presented method allows the consideration of the patient-specific biomechanical parameters; is more affordable, and the intraoperative X-ray exposure can be reduced. This new patient- and condition-specific approach may be widely used in revision spine surgeries or in challenging primary cases after its further clinical validation.

Individualized prediction of pedicle screw fixation strength with a finite element model

Pedicle screws are used for the treatment of a wide variety of spinal pathologies. A good screw holding power in bone is required for treatment success, but has so far not been predictable computationally. The goal of this study was to develop an automated tool able to predict patient-specific screw fixation strength through finite element simulation. We compared the simulation results with results from biomechanical pull-out tests performed on animal lumbar specimens. Experimental and simulation pull-out strengths were highly correlated [Formula: see text] and the mean error was 20.25%. The fixation strength was also associated to great extent with pull-out stiffness and strain energy, as well as the screw size and mean vertebral density.